Orthopedic brace having length-adjustable supports

ABSTRACT

An orthopedic brace having length adjustable supports is provided. The brace comprises upper and lower supports rotatably connected by a hinge. Each of the supports comprises an elongate portion having a channel along part of its length, and a sliding upright that nests within the channel. The upright is incrementally longitudinally translatable within the channel so that the length of the support is adjustable. Flanges are provided along the edges of the channel to prevent lateral separation of the upright from the stationary portion. A spring-biased button protrudes from an upper surface of the channel. The button cooperates with one of a plurality of holes in the upright, providing a positive lock to retain the upright in one of a number of predetermined positions within the channel. The upright is also completely removable from the channel. Removal of the upright from the channel shortens the brace. Straps cooperate with brackets on the supports and/or uprights to secure the brace to a patient&#39;s leg.

RELATED APPLICATION

[0001] This application claims priority to provisional application Ser.No. 60/255,521, filed on Dec. 12, 2000.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to orthopedic braces and, moreparticularly, to orthopedic braces having length adjustment capability.

[0004] 2. Description of the Related Art

[0005] Orthopedic braces are commonly employed after surgery or fortreatment of injury to a joint. Such braces generally serve to stabilizethe joint. In certain cases orthopedic braces limit joint flexion and/orextension in a controllable and adjustable manner to prevent re-injuryof the joint and to promote rehabilitation.

[0006] Some prior art orthopedic braces include length-adjustablesupport members. However, these braces typically comprise sidebarcomponents that are merely sandwiched together. This configuration makesthem susceptible to prying forces that tend to separate the components.

[0007] In addition, some prior art braces use threaded fasteners toconnect the sidebar components. Adjusting these braces requires ascrewdriver or turning a manual thumbscrew, both of which areinconvenient and time consuming. Such braces are also typically prone tofailure due to stripped fastener threads. Other braces rely uponfriction, as from tightening a lead screw, to hold the components of thebrace in the desired position. These braces, however, do not provide apositive lock, and are thus prone to disadvantageous slippage.

[0008] Some prior art braces use an all-aluminum construction. Machiningand forming aluminum, however, is relatively expensive and has certainphysical limitations. Aluminum thus limits the range of features andstyle that may be incorporated into the brace.

SUMMARY OF THE INVENTION

[0009] The preferred embodiments of the orthopedic brace have severalfeatures, no single one of which is solely responsible for theirdesirable attributes. Without limiting the scope of this orthopedicbrace as expressed by the claims that follow, its more prominentfeatures will now be discussed briefly. However, not all of thefollowing features are necessary to achieve the advantages of theorthopedic brace. Therefore, none of the following features should beviewed as limiting. After considering this discussion, and particularlyafter reading the section entitled “Detailed Description of thePreferred Embodiments,” one will understand how the features of thepreferred embodiments provide advantages over prior braces. One suchadvantage is length adjustability so that the amount of restraintoffered by the brace may be altered during a course of treatment and sothat one brace may fit differently sized patients. Another advantage isthat the brace includes a low profile that prevents the brace fromsnagging objects as the wearer moves about. The brace may bemanufactured from a combination of thermoplastic composite and metalthat enables the brace to harness the advantages of both materials.Further, the brace may have a length adjustment mechanism that isrecessed to prevent accidental activation.

[0010] One preferred embodiment of the orthopedic brace comprises afirst support, a second support, and a hinge assembly rotatablyconnecting the first and second supports. At least one of the first andsecond supports comprises an outer portion defining a longitudinalchannel and a telescoping upright movable in the channel to adjust alength of the support.

[0011] In another preferred embodiment, at least one strap is providedto wrap around the brace and a patient's leg to secure the brace to theleg.

[0012] In another preferred embodiment, at least one padded cuff isdisposed between the patient's leg and the brace to increase patientcomfort.

[0013] In another preferred embodiment, the upright is removable fromthe at least one of the first and second supports to shorten the overalllength of the brace.

[0014] In another preferred embodiment, a plurality of engagementsurfaces are provided along a length of the telescoping upright, and theouter portion includes an engagement member selectively engageable withthe engagement surfaces to lock the telescoping portion in place in thechannel.

[0015] In another preferred embodiment, the engagement member isrecessed within the upright when the engagement member engages one ofthe engagement surfaces.

[0016] In another preferred embodiment, the engagement member comprisesa button disposed within a recess in the channel and biased toward aconfiguration wherein a portion of the button protrudes from a surfaceof the channel.

[0017] In another preferred embodiment, the button has an oval shape inplan aspect.

[0018] In another preferred embodiment, the engagement surfaces compriseholes.

[0019] In another preferred embodiment, the holes have an oval shape inplan aspect.

[0020] In another preferred embodiment, the first and second supportsare curved about an axis that is parallel to a longitudinal axis of thebrace.

[0021] In another preferred embodiment, a cross-section of the first andsecond supports includes a first region having a first radius ofcurvature and a second region having a second radius of curvature longerthan the first radius of curvature.

[0022] In another preferred embodiment, the first region is locatedbetween the second region and a third region having the second radius ofcurvature.

[0023] In another preferred embodiment, the first and second supportsfurther comprise at least a first generally D-shaped ring on a firstside and a second generally D-shaped ring on a second side opposite thefirst side.

[0024] In another preferred embodiment, the first and second rings areadjacent the hinge assembly.

[0025] In another preferred embodiment, the upright comprises at least afirst generally D-shaped ring on a first side and a second generallyD-shaped ring on a second side opposite the first side.

[0026] In another preferred embodiment, the first and second rings arelocated at an end of the upright opposite the hinge assembly.

[0027] In another preferred embodiment, the hinge assembly comprisesflexion-limiting stops.

[0028] In another preferred embodiment, the hinge assembly comprisesextension-limiting stops.

[0029] In another preferred embodiment, the orthopedic brace comprises afirst support, a second support, and a hinge assembly rotatablyconnecting the first and second supports. At least one of the first andsecond supports comprises a first portion constructed of a thermoplasticcomposite and a second portion constructed of a metal.

[0030] In another preferred embodiment, the first portion comprises anouter portion defining a longitudinal channel.

[0031] In another preferred embodiment, the second portion comprises atelescoping upright movable in the channel to adjust the length of thesupport.

[0032] In another preferred embodiment, the first portion is connectedto a metal hinge plate.

[0033] In another preferred embodiment, the hinge plate is insert moldedwithin the first portion.

[0034] In another preferred embodiment, a portion of the hinge plate isbendable about an axis that is perpendicular to an axis of rotation ofthe hinge assembly.

[0035] In another preferred embodiment, the orthopedic brace comprises afirst length-adjustable support and a second length-adjustable support.Each support includes a longitudinal channel and a sliding uprightwithin the channel. A hinge assembly rotatably connects the first andsecond supports. Each sliding upright includes a plurality of throughholes, and a floor of each channel includes a spring-biased button. Thebutton is engageable with each hole such that the button positivelylocks a position of the upright with respect to the channel. The uprightis slidable within the channel when the button is depressed.

[0036] In another preferred embodiment, each support includes acurvature about a longitudinal axis thereof such that substantially allof a surface of each support that faces a patient's leg contacts theleg.

[0037] In another preferred embodiment, each support further comprises aplurality of brackets that are adapted to receive flexible straps forsecuring the brace to a patient's leg.

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The preferred embodiments of the orthopedic brace, illustratingits features, will now be discussed in detail. These embodiments depictthe novel and non-obvious orthopedic brace shown in the accompanyingdrawings, which are for illustrative purposes only. These drawingsinclude the following figures, in which like numerals indicate likeparts:

[0039]FIG. 1 is a perspective view of a preferred embodiment of theorthopedic brace of the present invention including a right support anda left support, padded cuffs and straps;

[0040]FIG. 2 is a partially exploded perspective view of the brace andpadded cuffs of FIG. 1;

[0041]FIG. 3 is a perspective view of another preferred embodiment ofthe orthopedic brace including a right support;

[0042]FIG. 4 is an exploded perspective view of a calf portion of thebrace of FIG. 3;

[0043]FIG. 4A is a partially exploded perspective view of the calfportion of FIG. 4;

[0044]FIG. 5A is a top plan view of a link bar of a thigh portion thebrace of FIG. 3;

[0045]FIG. 5B is a bottom plan view of the link bar of FIG. 5A;

[0046]FIG. 5C is a right-side elevation view of the link bar of FIG. 5A;

[0047]FIG. 5D is a front elevation view of the link bar of FIG. 5A;

[0048]FIG. 5E is a detail view of a recess portion of the link bar ofFIG. 5A;

[0049]FIG. 6A is a top plan view of a link bar of a calf portion thebrace of FIG. 3;

[0050]FIG. 6B is a bottom plan view of the link bar of FIG. 6A;

[0051]FIG. 6C is a right-side elevation view of the link bar of FIG. 6A;

[0052]FIG. 6D is a front elevation view of the link bar of FIG. 6A;

[0053]FIG. 7A is a top plan view of a hinge plate of the link bar ofFIG. 5A;

[0054]FIG. 7B is a right-side elevation view of the hinge plate of FIG.7A;

[0055]FIG. 8A is a top plan view of a hinge plate of the link bar ofFIG. 6A;

[0056]FIG. 8B is a right-side elevation view of the hinge plate of FIG.8A;

[0057]FIG. 9A is a top plan view of a sliding upright of a calf portionof the brace of FIG. 3;

[0058]FIG. 9B is a bottom plan view of the sliding upright of FIG. 9A;

[0059]FIG. 9C is a front elevation view of the sliding upright of FIG.9A;

[0060]FIG. 9D is a right-side elevation view of the sliding upright ofFIG. 9A;

[0061]FIG. 9E is a left-side elevation view of the sliding upright ofFIG. 9A;

[0062]FIG. 10A is a top plan view of a sliding upright of a thighportion of the brace of FIG. 3;

[0063]FIG. 10B is a bottom plan view of the sliding upright of FIG. 10A;

[0064]FIG. 10C is a front elevation view of the sliding upright of FIG.10A;

[0065]FIG. 10D is a right-side elevation view of the sliding upright ofFIG. 10A;

[0066]FIG. 10E is a left-side elevation view of the sliding upright ofFIG. 10A;

[0067]FIG. 11 is a perspective view of a preferred embodiment of theorthopedic brace including a right support and a left support, paddedcuffs and straps, wherein sliding uprights of each support have beenremoved; and

[0068]FIG. 12 is a partially exploded perspective view of the brace andpadded cuffs of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0069]FIGS. 1 and 2 illustrate a preferred embodiment of an orthopedicbrace 20. In the illustrated embodiment, the orthopedic brace 20 is aknee brace. However, one of skill in the art will appreciate thatcertain features of the orthopedic brace 20 are applicable to othertypes of braces as well, such as arm braces, ankle braces, neck braces,and the like.

[0070] The embodiment of FIGS. 1 and 2, which is adaptable for use oneither the left or the right leg of a patient, comprises a firstelongate support 22 for positioning along the right side of thepatient's leg, and a second elongate support 24, for positioning alongthe left side. If desired, only one support may be used for particularapplications. In the two support configuration, however, the twosupports 22, 24 preferably are mirror images of one another.

[0071] The supports 22, 24 are secured to a patient's leg with straps 26that wrap around the circumference of the leg. In the embodimentillustrated in FIG. 1, six straps 26 are provided. Those of skill in theart will appreciate, however, that fewer or more straps may be used. Aplurality of padded cuffs 28 disposed between the supports 22, 24 andthe leg provide padding and increase patient comfort. Those of skill inthe art will also appreciate that the cuffs 28 merely enhance thewearability of the brace 20, and are not an essential component of thebrace 20. A pad 30 may be secured to an inside surface of each support22, 24 near a midpoint of each support 22, 24. In a preferredembodiment, the cuffs 28 and pads 30 each comprise a layer of foampadding and a layer of a loop portion of a hook-and-loop fastener.

[0072] In another preferred embodiment, an inside surface of the cuffs28 and/or pads 30 comprises a fabric. This surface contacts thepatient's leg. Therefore, the fabric is preferably any material that iscomfortable for wear against the skin. A preferred material is nylon. Ofcourse, the cuffs need not include a fabric layer on an inside surface.Preferably, however, the cuffs do not irritate the patient's skin.

[0073] The loop portion of a hook-and-loop fastener forms an outsidesurface of the cuffs 28 and pads 30. The outside surface contacts aplurality of inserts 32 which may be disposed between the cuffs 28 andpads 30 and the supports 22, 24. A first face of each insert comprises ahook portion of a hook-and-loop fastener and faces the outside surfaceof the cuffs 28 and pads 30. A second face, opposite the first face,adhesively attaches the inserts 32 to the inside surfaces of thesupports 22, 24. The inserts 32 thus removably secure the supports 22,24 to the cuffs 28 and pads 30 to prevent migration of the brace 20relative to the cuffs 28 and pads 30. Rather than including the inserts32, a variety of other configurations could be used to maintain therelative positions of the brace 20 and cuffs 28. For example, fastenersother than hook-and-loop could be used. Alternatively, the cuffs couldbe manufactured from neoprene, or another material that has a highcoefficient of static friction.

[0074]FIG. 3 illustrates the right support 22 in detail. In theillustrated embodiment, the support 22 includes a thigh portion 34 and acalf portion 36. A hinge portion 38 rotatably connects the thigh portion34 and calf portion 36. The hinge portion 38 may comprise any of avariety of well-known hinges. However, examples of preferred hinge typesare described in U.S. Pat. Nos. 5,921,946 to Tillinghast, and 5,443,444to Pruyssers, the entirety of which are incorporated herein byreference.

[0075]FIG. 4 is an exploded perspective view of the calf portion 36 ofthe right support 22. The thigh portion 34 is substantially identical tothe calf portion 36, with a few exceptions. The calf portion 36preferably comprises a link bar 39, a sliding upright 40, and a button42. When assembled, the button 42 nests inside the link bar 39, asdescribed below.

[0076] The link bar 39 in turn is constructed of two pieces, as shown inFIGS. 5A-5E and 6A-6D. A first piece, or hinge plate 44, 48, is fixedlyconnected at a first end to a second piece, or channel member 46. Eachof the thigh portion 34 and calf portion 36 includes an identicalchannel member 46. A second end of the hinge plate 44, 48 is rotatablyconnected to the hinge portion 38 (FIG. 3). In the embodiment shown, theshape of the hinge plate 44 comprising the thigh portion 34 differs fromthe shape of the hinge plate 48 comprising the calf portion 36. Theshapes and functions of the hinge plates 44, 48 are described in detailin the above-referenced patent to Tillinghast.

[0077] FIGS. 7A-8B illustrate preferred embodiments of the hinge plates44, 48. Each hinge plate 44, 48 includes a base portion 50 that issecured to the corresponding channel member 46, and an extended portion52, 54 that is disposed adjacent the channel member 46. The base portion50 may be embedded within the channel member 46, or may be secured tothe channel member 46 in another appropriate fashion, such as with boltsor rivets. The base portion 50 of each hinge plate 44, 48 is a flat,substantially rectangular plate preferably having at least one throughhole 56 and at least one notch 58 along a side 60 thereof.

[0078] Referring to FIG. 8B, the extended portion 52 of the calf hingeplate 48 includes a ramp portion 62 that extends at an angle from thebase portion 50, and a second flat, substantially rectangular plate 64that lies in a plane that is substantially parallel to that of the baseportion 50. The extended portion 54 of the thigh hinge plate 44 (FIGS.7A and 7B) comprises an oblong flat plate 66 extending at an angle fromthe base portion 50. The plate 66 preferably has a multi-contoured edge68 that includes a plurality of cammed surfaces 70, extension limitinglands 72, and flexion limiting lands 74. The surface of the plate 66includes a through bore 76 near an end of the plate 66 opposite the baseportion 50, at least one elongate trough 78 extending substantially inthe lengthwise direction of the plate 66, and a stepped slot 80extending in substantially the same direction. The surface features ofthe hinge plates 44, 48 facilitate the operation of the hinge 38, whichis described in detail in the above-referenced patent to Tillinghast.

[0079] The hinge plates 44, 48 are preferably constructed of aluminum orother pliable metal. Because of the wide variety of shapes and sizes ofhuman legs, it is advantageous for a treating physician to be able toreadily bend the knee brace 20 to more comfortably and effectively fitthe contours of the leg. Aluminum and other pliable metals arerelatively easy to bend by hand. These metals thus advantageouslyprovide formability to the knee brace 20.

[0080] In the embodiment illustrated in FIGS. 5A-5E and 6A-6D, thechannel member 46 is shaped as an elongate bar, having an integral,substantially D-shaped bracket 82 near each corner thereof. The brackets82 project outwardly from the sides 84 of the channel member 46. Eachbracket 82 defines a central slot 86 that is adapted to receive one ofthe straps 26. The straps 26 cooperate with the brackets to secure thebrace 20 to the patient's leg.

[0081] A recess 88, elliptical in plan aspect, is provided in a floor 90of each channel member 46 near an end 92 of the channel member 46opposite the hinge plate 44, 48. The recess 88 houses the button 42(FIG. 4), which is sized and shaped to fit within the interior of therecess 88. A spring 94 is disposed around a post 96 within the recess88. A first end of the spring 94 abuts a lower surface of the button 42,and a second end of the spring 94 abuts a floor of the recess 88. Thespring 94 thus biases the button 42 outwardly from the interior of therecess 88, such that an upper portion of the button 42 protrudes fromthe recess 88 (FIG. 4A). Retaining tabs 98 on the lower end of thebutton 42 extend through holes 100 (FIG. 5E) in the channel member 46and prevent the button 42 from being completely expelled from the recess88.

[0082] An inner surface 102 (FIGS. 5B and 6B) of the channel members 46rests against the padded cuffs 28 when the brace 20 is worn. The innersurface 102 is preferably curved in cross-section to more closely fitthe curved surface of the leg. The curvature helps to prevent thesupports 22, 24 from shifting relative to the cuffs 28. An outer surface103 (FIG. 5C and 6C) is also preferably curved in cross-section. Thecurved outer surface 103 gives the supports 22, 24 a more streamlinedappearance, thereby reducing the risk that the supports 22, 24 will snagobjects when the patient engages in physical activity. Those of skill inthe art will appreciate that the supports 22, 24 need not include anycurvature. Supports having substantially flat cross-sections do notdepart from the spirit of the brace 20.

[0083] In a preferred embodiment, the inner surface 102 of the channelmember 46 includes portions having different radii of curvature. Thecenter portion 104 of the inner surface, as viewed from the side (FIGS.5C and 6C), has a relatively short radius of curvature, while the outerportions 106 on either side of the center portion 104 each have a longerradius of curvature. The larger radius is selected to conform to thecurved surface of the leg in order to increase patient comfort andprovide a streamlined profile for the brace 20. The smaller radius ofcurvature of the center portion 104 increases the rigidity, or bendingstrength, of the channel member 46 without adding additional material.Additional material would tend to increase the weight of the channelmember 46 and compromise its low profile. The small-radius centerportion 104 also creates a gap between the center portion 104 of theinner surface 102 and the outer surface of the cuffs 28. This gapprovides room for the inserts 32 and enables the button 42 to bedepressed more easily while the brace 20 is worn. Without the gap, theretaining tabs 98 (FIG. 4) may interfere with the cuffs 28 when thebutton 42 is depressed.

[0084] The floor 90 of each channel member 46 is preferably similarlycurved, and includes a pair of oppositely disposed flanges 108 at thesides thereof. The flanges 108 extend along most of the length of thechannel member 46, creating a channel 110 that is substantially C-shapedin an end view (FIGS. 5C and 6C). The channel 110 has an open top. Afirst end 112 (FIGS. 5A and 5C) of the channel 110 near the hinge plate44, 48 is closed, while a second end 92 of the channel 110 opposite thefirst end 112 is open.

[0085] The channel members 46 (FIGS. 5A and 6A) are preferablyconstructed of a composite material, and are formed by an insert moldingprocess. A composite consisting of 83% thermoplastic nylon and 17% glassis a particularly preferred material for the channel members 46. Duringthe insert molding process, the base portions 50 of the hinge plates 44,48 are placed in an insert mold, after which a liquid composite isinjected into the mold. The liquid composite surrounds the base portions50, filling the holes 56 and notches 58. The composite that fills theholes 56 and notches 58 greatly strengthens the connection between thehinge plates 44, 48 and channel members 46 by increasing the pull-outstrength of the hinge plates 44, 48. Rather than securing the hingeplates 44, 48 to the channel members 46 by an insert molding process,other conventional methods of attachment could be used. For example,screws or rivets may be used to secure the hinge plates 44, 48 to thechannel members 46.

[0086] The combination of metal and composite in the supports 22, 24imparts several advantages to the brace 20. First, insert molding is arelatively inexpensive process that enables complicated geometries to beformed with ease. Thus, even the complex shape of the channel members46, which have contoured surfaces, ridges and tight interior comers, canbe manufactured at relatively low cost. Surfaces and shapes such asthese could not reasonably be formed from metal, at least not withoutundesirable additional cost. Second, the use of a bendable metal allowsthe brace 20 to be custom formed by a physician to fit the exactcontours of the patient's leg. Thus, providing a link bar 39 (FIGS. 5Aand 6A) that is formed from both metal and thermoplastic compositeallows preferred embodiments of the brace 20 to include both of theseadvantages, rather than just one or the other.

[0087] A preferred embodiment of the sliding upright 40 is illustratedin detail in FIGS. 9A-9E. A second sliding upright 114, illustrated indetail in FIGS. 10A-10E, is substantially identical to the upright 40,except that the upright 40 includes an extension section 116 such thatthe upright 40 is longer than the upright 114. The difference in lengthsbetween the upright 40 and upright 114 enables the brace 20 to betterfit the patient's leg. Those of skill in the art will appreciate,however, that uprights of any suitable length, including uprights havingequal lengths, are within the scope of the present orthopedic brace 20.

[0088] The uprights 40, 114 comprise an elongate bar with a pair ofbrackets 118 at one end thereof. The uprights 40, 114 nest within thechannel members 46 of the calf portion 36 and thigh portion 34,respectively. The brackets 114 are similar in size, shape andorientation to the brackets 82 of the channel members 46, and aredesigned to receive the straps 26 within a central slot 120 for securingthe brace 20 to the patient's leg. A center of an end 119 of eachupright 40, 114 adjacent the brackets includes an indentation 121. Theindentations 121 increase patient comfort by preventing interferencebetween the sliding uprights 40, 114 and the patient's malleoli. Thoseof skill in the art will appreciate that the indentations are notnecessary to achieve the objects of the orthopedic brace 20.

[0089] Each of the uprights 40, 114 has a curved cross-section (FIGS.9D-9E and 10D-10E) of substantially the same radius as the floor 90 ofthe channel member 46. The curved contour not only allows the uprights40, 114 to fit within the channels 110, but it also provides theuprights 40, 114 with greater rigidity. As with the channel members 46,discussed above, the uprights 40, 114 need not be curved incross-section. Preferably, however, the uprights have appropriatecross-sectional shapes to fit within the channels in the channelmembers. The uprights 40, 114 may also be provided with a cross-sectionof variable thickness, if desired, to further increase the stiffness ofthe uprights 40, 114.

[0090] The thickness of the uprights 40, 114 near the edges 122 thereofallows the uprights 40, 114 to fit beneath the flanges 108 of thechannel members 46. The uprights 40, 114 are thus configured to enterthe open ends 92 of the channels 110 and slide longitudinally within thechannels 110. The flanges 108 extend over the edges 122 of the uprights40, 114 to prevent lateral separation of the uprights 40, 114 from thechannel members 46. The slidability of the uprights 40, 114 within thechannels 110 allows the length of the brace 20 to be adjusted.

[0091] Each of the uprights 40, 114 contains a plurality of spaced-apartelliptical holes 124 along a longitudinal axis thereof. The holes 124desirably have substantially the same size, shape and orientation as thebutton 42. As the uprights 40, 114 slide within the channels 110, theholes 124 consecutively pass over the button 42. As each hole 124passes, the biasing spring 94 forces the button 42 into the hole 124.The button 42 prevents further translation of the uprights 40, 114through the channels 110, until an operator depresses the button 42 andholds it down while translating the uprights 40, 114 within the channels110. The button 42 and corresponding holes 124 may be of any suitableshape.

[0092] The relatively large size and elliptical shape of the holes 110and the button 42 allow the button 42 to be easily actuated by a fingeror thumb of the operator. This configuration greatly reduces thedifficulty of adjusting the brace 20, because the operator has one handfree to manipulate the uprights 40, 114 while holding down the button 42with the finger or thumb.

[0093] When the button 42 is disposed within a hole 124, a top surface126 (FIG. 4) of the button 42 is preferably flush with, or recessedbelow, the outer surface of the uprights 40, 114 as in FIG. 3. Thisarrangement reduces the risk that the button 42 will be accidentallyactivated if the wearer, for example, bumps into a table or chair.

[0094] The length adjustability of the brace 20, having push-buttonactivation, provides the brace 20 with a number of advantages. First,the brace 20 is adapted to fit a wide variety of patients without theneed for complicated adjustments. To fit the brace 20 to a patient, aphysician individually adjusts the length of the thigh portion 34 andcalf portion 36. The adjustment procedure for each portion 34, 36 issubstantially identical, and the physician may adjust the portions 34,36 in any order. To illustrate, however, adjustment of the thigh portion34 will be described.

[0095] The physician depresses the button 42 by applying pressure to thebutton top surface 126 (FIG. 3) with his or her thumb or finger. When atleast a leading edge of the button top surface 126 is below the hole124, the upright 114 is freely translatable within the channel 110 (FIG.5C) in either direction. Because the button 42 is biased outwardly bythe spring 94 (FIG. 4), as the physician translates the upright 114 thebutton 42 will automatically pop into each successive hole 124 as eachpasses over the button 42, thereby locking the upright 114 in place withrespect to the channel member 46. Each time the button 42 pops out, thephysician pushes it back in and continues translating the upright 114until the button 42 pops into the desired hole 124. When the button 42pops into the desired hole 124, the upright 114 is securely locked withrespect to the channel member 46.

[0096] Second, since preferred embodiments of one brace 20 will fit manypatients of different sizes, hospitals need not maintain a largeinventory of differently sized braces. With some prior art braces,length adjustment effectively means substituting a brace of one sizewith a differently sized brace. Thus, hospitals must maintain a largeinventory of braces of all different sizes in order to accommodate thewide variety of patients that they regularly treat. With preferredembodiments of the brace 20, hospitals need only keep a supply of onebrace 20. Physicians then adjust the length of the brace 20 as needed tofit individual patients.

[0097] Third, as the patient progresses through therapy, it is oftendesirable to reduce the amount of support provided by the brace 20, suchas by shortening the length of the brace 20. With preferred embodimentsof the brace 20, however, the uprights 40, 114 may be retracted todecrease the overall length of the brace 20. Alternatively, if an evenshorter brace 20 is desired, one or both uprights 40, 114 may becompletely removed from their respective channels 110. The remaininglength of the supports 22, 24, which consists of the link bars 39 andthe hinge portion 38, may then be used in isolation, as shown in FIGS.11 and 12. Removal of the uprights 40, 114 is quick and easy, requiringonly that the button 42 be depressed while the uprights 40, 114 aredrawn completely out of the channels 110. The brace 20 is thus far moreversatile than prior art designs.

[0098] The embodiment of the brace 20 depicted in FIGS. 11 and 12includes shells 128 disposed between the supports 22, 24 and the cuffs28. The shells 128 comprise semi-rigid members that aid in providingeven compression about the patient's leg. Preferably the shells 128 areconstructed of a plastic. However, any semi-rigid material could beused.

[0099] In the pictured embodiment, each shell 128 is shapedsubstantially as a half-cylinder. Thus, two shells 128 comprise athigh-encircling portion, and two shells 128 comprise a calf-encirclingportion. Those of skill in the art will appreciate that the shells 128may be constructed in a variety of alternative ways. For example, thethigh-or calf-encircling portion could be shaped as a complete cylinderwith a longitudinal split so that the cylinder may be wrapped around thepatient's leg. Those of skill in the art will also appreciate that theshells 128 may be used with the embodiment of the brace 20 depicted inFIGS. 1 and 2. Finally, those of skill in the art will also appreciatethat the shells 128 are not necessary to achieve the objects of theorthopedic brace 20.

SCOPE OF THE INVENTION

[0100] The above presents a description of the best mode contemplatedfor the present orthopedic brace having length-adjustable supports, andof the manner and process of making and using it, in such full, clear,concise and exact terms as to enable any person skilled in the art towhich it pertains to make and use this brace. This brace is, however,susceptible to modifications and alternate constructions from thatdiscussed above which are fully equivalent. Consequently, it is not theintention to limit this brace to the particular embodiments disclosed.On the contrary, the intention is to cover all modifications andalternate constructions coming within the spirit and scope of the braceas generally expressed by the following claims, which particularly pointout and distinctly claim the subject matter of the brace.

What is claimed is:
 1. An orthopedic brace, comprising: a first support;a second support; and a hinge assembly rotatably connecting the firstand second supports, wherein at least one of the first and secondsupports comprises an outer portion defining a longitudinal channel anda telescoping upright movable in the channel to adjust a length of thesupport.
 2. The orthopedic brace of claim 1, further comprising at leastone flexible strap encircling a portion of the brace and a portion of apatient's leg to secure the brace to the leg.
 3. The orthopedic brace ofclaim 2, further comprising at least one padded cuff disposed betweenthe brace and the leg.
 4. The orthopedic brace of claim 1, wherein theupright is removable from the at least one of the first and secondsupports to shorten an overall length of the brace.
 5. The orthopedicbrace of claim 1, wherein a plurality of engagement surfaces areprovided along a length of the telescoping upright, and the outerportion includes an engagement member selectively engageable with atleast one of the engagement surfaces to lock the telescoping portion inplace in the channel.
 6. The orthopedic brace of claim 5, wherein theengagement member is recessed within the upright when the engagementmember engages the at least one of the engagement surfaces.
 7. Theorthopedic brace of claim 6, wherein the engagement member comprises abutton disposed within a recess in the channel and biased toward aconfiguration wherein a portion of the button protrudes from a surfaceof the channel.
 8. The orthopedic brace of claim 7, wherein the buttonhas an oval shape in plan aspect.
 9. The orthopedic brace of claim 5,wherein the engagement surfaces comprise holes.
 10. The orthopedic braceof claim 9, wherein the holes have an oval shape in plan aspect.
 11. Theorthopedic brace of claim 1, wherein the first and second supports arecurved about an axis that is parallel to a longitudinal axis of thebrace.
 12. The orthopedic brace of claim 11, wherein a cross-section ofthe first and second supports includes a first region having a firstradius of curvature and a second region having a second radius ofcurvature longer than the first radius of curvature.
 13. The orthopedicbrace of claim 12, wherein the first region is located between thesecond region and a third region having the second radius of curvature.14. The orthopedic brace of claim 1, wherein the first and secondsupports further comprise at least a first generally D-shaped ring on afirst side and a second generally D-shaped ring on a second sideopposite the first side.
 15. The orthopedic brace of claim 14, whereinthe first and second rings are adjacent the hinge assembly.
 16. Theorthopedic brace of claim 1, wherein the upright comprises at least afirst generally D-shaped ring on a first side and a second generallyD-shaped ring on a second side opposite the first side.
 17. Theorthopedic brace of claim 16, wherein the first and second rings arelocated at an end of the upright opposite the hinge assembly.
 18. Theorthopedic brace of claim 1, wherein the hinge assembly comprisesflexion-limiting stops.
 19. The orthopedic brace of claim 1, wherein thehinge assembly comprises extension-limiting stops.
 20. An orthopedicbrace, comprising. a first support; a second support; and a hingeassembly rotatably connecting the first and second supports, wherein atleast one of the first and second supports comprises a first portionconstructed of a thermoplastic composite and a second portionconstructed of a metal.
 21. The orthopedic brace of claim 20, whereinthe first portion comprises an outer portion defining a longitudinalchannel.
 22. The orthopedic brace of claim 21, wherein the secondportion comprises a telescoping upright movable in the channel to adjusta length of the support.
 23. The orthopedic brace of claim 20, whereinthe first portion is connected to a metal hinge plate.
 24. Theorthopedic brace of claim 23, wherein the hinge plate is insert moldedwithin the first portion.
 25. The orthopedic brace of claim 23, whereina portion of the hinge plate is bendable.
 26. An orthopedic brace,comprising: a first length-adjustable support including a longitudinalchannel and a sliding upright slidably engaging the channel; a secondlength-adjustable support including a longitudinal channel and a slidingupright slidably engaging the channel; and a hinge assembly rotatablyconnecting the first and second supports, wherein each sliding uprightincludes a plurality of through holes, and a floor of each channelincludes a spring-biased button engageable with each hole such that thebutton positively locks a position of the upright with respect to thechannel and the upright is slidable within the channel when the buttonis depressed.
 27. The orthopedic brace of claim 26, wherein each supportincludes a curvature about a longitudinal axis thereof such thatsubstantially all of a surface of each support that faces a patient'sleg contacts the leg.
 28. The orthopedic brace of claim 26, wherein eachsupport further comprises a plurality of brackets that are adapted toreceive flexible straps for securing the brace to a patient's leg.